Lighting systems of tailgates with plastic glazing

ABSTRACT

A plastic glazing (100) of a tailgate of a vehicle is provided, the plastic glazing (100) comprising: a first translucent component (302); a second translucent component (304) molded onto the first translucent component (302), wherein the second translucent component (304) comprises a color, wherein the plastic glazing (100) is of one-piece molded plastic construction, wherein an overlapping portion of the first translucent component (302) and the second translucent component (304) forms a lens of a first molded light assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit from U.S. Provisional ApplicationNo. 62/215,082 filed on Sep. 7, 2015, which is hereby incorporated byreference in its entirety for all purposes as if fully set forth herein.

BACKGROUND Technical Field

The present disclosure relates to tailgates and, specifically, tolighting systems of tailgates of a vehicle having plastic glazing.

Technical Background

Vehicles such as sports utility vehicles (“SUVs”), vans, hatchbacks, andthe like include a structural component known as a tailgate. Thetailgate is provided to open or close an opening formed at a rearportion of a vehicle. The tailgate is typically hinged to the mainvehicle body, for example, along its upper end, such that it can swingopen and close. Examples of tailgates include a rear door tailgate or atruck lid tailgate.

The tailgate may support one or more other vehicle components, such as arear window and one or more light assemblies (e.g., a supplemental brakelight, a puddle light). The tailgate may also be adjacent to bodycavities into which rear lamp units are inserted. These parts and otherparts may add to the cost and complexity of assembling a vehicle.

Light assemblies in vehicles, in particular, comprise a large number ofseparate components. For example, a typical vehicle may have severaldifferent types of lights, including, for example, parking lights, turnindicator lights, brake lights, and the like. Each of these lights maybe made from many parts. These parts add to the cost and complexity ofassembling a vehicle. Accordingly, as recognized in U.S. Pat. No.7,048,423 (“the '423 patent”), it desirable to have a lighting assemblywith fewer parts. The '423 patent discloses an integrated light assemblyincluding a plurality of lamps 210, 216 enclosed in a housing 202, whichmay serve as a lens for the lamps, and mounted on a substrate 204.Because the lamps 210, 216 share a common substrate and lens, theadditional cost of having a separate lamp unit is eliminated. Thisstructure disclosed in the '423 patent, however, has many drawbacks. Forone, because multiple lamps are mounted together in a single housingwithout sidewalls or reflectors for directing the angle of their light,the structure does not account for haziness issues. Moreover, if twolights of varying color are mounted in the housing, the structuredisclosed in the '423 patent does not have a way of preventing coloroverlap. These drawbacks may limit the use of such a light assembly in avehicle under state and federal regulations governing vehicle lightingrequirements. Thus, while the '423 patent discloses an integrated partfor a vehicle, its application may be limited.

Moreover, conventional light assemblies in vehicles, including the onedescribed in the '423 patent, remain separate from other vehiclecomponents. In particular, a light assembly may have a lens portion anda housing portion that are separate from the remaining components of avehicle. Thus, while a light assembly may be placed behind a translucentcomponent of a vehicle, such as, for example, a glass exterior, thelight assembly may have a separate lens for transmitting a light to anexterior of the vehicle. And while a light assembly may be supported inplace in a vehicle by another vehicle component, the light assembly mayhave a separate housing unit for supporting its light source. Suchportions of a light assembly may add to the overall weight of a vehicle,and the overall complexity and cost of manufacturing and assembling avehicle.

Inhomogeneities such as seams and openings between separate vehiclecomponents may also add to the cost of assembling, sealing and/orinsulating an interior of the vehicle and/or its components. Moreoversuch seams and openings may cause aerodynamic inefficiencies and disturbthe vehicle's overall aesthetical appearance. Additional components mayalso be required to connect separate vehicle components to one another,which may add to the overall weight of a vehicle.

The present disclosure aims to solve these problems and other problemsin the prior art.

SUMMARY

In accordance with the purpose(s) of the invention, as embodied andbroadly described herein, this disclosure, in one aspect, relates tovehicle components, including tailgates, and to lighting systems oftailgates with plastic glazing.

As will be apparent from the present disclosure, problems and/orobjectives for improvement with respect to a tailgate including plasticglazing, as described herein, may include providing a tailgate thatintegrates one or more other components of a vehicle, thereby reducing atotal number of components of a vehicle and reducing the complexity andcost of assembling a vehicle. Such problems and/or objectives forimprovement also may include providing a tailgate that reduces a numberof inhomogeneities, seams, and other faults along a surface of avehicle, thereby increasing an aesthetic appearance of the vehicle andincreasing aerodynamic performance. Such problems and/or objectives forimprovement further may include providing a tailgate that conceals oneor more other features of a vehicle, such as, for example, a lightassembly or unit, thereby increasing an aesthetic appearance of thevehicle.

Problems and/or objectives for improvement with respect to a tailgate,as described herein, may also include providing a tailgate withintegrated lighting functions. For example, the present disclosure mayprovide a tailgate having a plastic glazing that functions as a lens ofa molded light assembly. The molded light assembly may be, for example,a tail lamp, a turn signal light, a puddle light, a license plate light,or an interior light. A housing unit connected to the back of theplastic glazing may support and isolate the molded light assemblies fromone another, thereby preventing any color overlap between the variouslight assemblies. The housing unit may also remove the need for aseparate housing unit for each molded light assembly. As such, thehousing unit and the plastic glazing of the tailgate may reduce a numberof components required to assemble the lighting system of a vehicle. Theplastic glazing may also be made using an automated, machine-based,injection molding process, further streamlining production and reducinglabor costs.

Problems and/or objectives for improvement with respect to a tailgate,as described herein, may also include replacing certain heaviercomponents of a vehicle with plastic components. For example, thepresent disclosure may provide a tailgate formed entirely of plasticcomponents, whereby a translucent portion of the tailgate that istransparent may serve as a rear window instead of a glass component. Theplastic may weigh less than a glass window, and may also have strongerstructural qualities.

Problems and/or objectives for improvement with respect to a tailgate,as described herein, may also include incorporating a texture, marking,or the like into a plastic glazing of a tailgate in order to enhancecertain lighting features of the tailgate. The texture, marking, etc.may affect the passage of light through the plastic glazing to serveboth a functional and aesthetical purpose. For example, the plasticglazing may comprise a texture along a region that serves as a lens of amolded light assembly to disperse light emitted by the molded lightassembly to satisfy regulatory requirements and/or produce a certainaesthetical effect.

Accordingly, aspects of the present disclosure provide plastic glazingof a tailgate of a vehicle, the plastic glazing comprising: a firsttranslucent component; a second translucent component molded onto thefirst translucent component, wherein the second translucent componentcomprises a color, wherein the plastic glazing is of one-piece moldedplastic construction, wherein an overlapping portion of the firsttranslucent component and the second translucent component forms a lensof a first molded light assembly.

Additional aspects of the invention will be set forth in part in thedescription which follows, and in part will be obvious from thedescription, or can be learned by practice of the invention. Theadvantages of the invention will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description, isbetter understood when read in conjunction with the appended drawings.There is shown in the drawings example embodiments, and the presentinvention is not intended to be limited to the specific embodiments andmethods disclosed.

FIG. 1 is a schematic view of a front of a first exemplary plasticglazing of a tailgate in accordance with an embodiment of the presentdisclosure.

FIG. 2 is a deconstructed view of a tailgate assembly including thefirst exemplary plastic glazing depicted in FIG. 1 and a housing unit inaccordance with an embodiment of the present disclosure.

FIG. 3 is a partial cross-sectional view of the first exemplary tailgateglazing depicted in FIG. 1 with a partial cross-sectional view of ahousing unit in accordance with an embodiment of the present disclosure.

FIG. 4 is a partial cross-sectional view of the first exemplary tailgateglazing depicted in FIG. 1 with a partial cross-sectional view of ahousing unit in accordance with an alternative embodiment of the presentdisclosure.

FIG. 5 is a schematic view of a front of a second exemplary plasticglazing of a tailgate having a logo or marking in accordance with anembodiment of the present disclosure.

FIG. 6 is a schematic view of an outer panel of a vehicle configured tofit together with the second exemplary plastic glazing depicted in FIG.5 in accordance with an embodiment of the present disclosure.

FIG. 7 is a schematic view the second exemplary plastic glazing depictedin FIG. 5 assembled with the outer panel depicted in FIG. 6 inaccordance with an embodiment of the present disclosure.

FIG. 8 is a partial cross-sectional view of the second exemplary plasticglazing depicted in FIG. 5.

FIG. 9 is a schematic view of a front of a third exemplary plasticglazing of a tailgate having applique lighting in accordance with anembodiment of the present disclosure.

FIG. 10 is a cross sectional view of a vehicle having the thirdexemplary plastic glazing depicted in FIG. 9.

FIG. 11 is an enlarged view of the cross-sectional view of the vehiclehaving the third exemplary plastic glazing depicted in FIG. 9.

DESCRIPTION

Aspects of the disclosure will now be described in detail with referenceto the drawings, wherein like reference numerals designate identical orcorresponding parts throughout the several views, unless specifiedotherwise.

Systems and methods disclosed herein provide a tailgate or lift gateand, in particular, a tailgate having a plastic glazing having aone-piece monolithic construction. The one-piece monolithic structurecan be fabricated in one piece using an injection molding process.Vehicles of a hatchback or van configuration typically include an accessopening at their rear and a tailgate that selectively opens and closesthe access opening. The tailgate may be mounted on the main body of thevehicle using a hinged connection. As such, the tailgate may operatelike a hinged flap, which swings open and close along the hingedconnection. The tailgate is typically operated manually but may also beoperated electronically using a power actuator.

The tailgate may support one or more other vehicle components such as arear glass window, a logo or marking, a light assembly or unit, alicense plate holder, etc. These components are usually attached to thetailgate using screws or other connectors or an adhesive. In its closedposition, the tailgate may also be adjacent to one or more cavities inthe body of the vehicle for receiving a rear lamp unit or other lightunit.

In order to reduce the number of separate components of a vehicle,systems and methods disclosed herein may provide an integrated tailgateassembly including and/or integrating one or more other vehiclecomponents. For example, systems and methods disclosed herein mayprovide a tailgate having a plastic glazing including a rear window. Theplastic glazing of the tailgate may be constructed of a thermoplasticpolymer including a portion that is clear as the rear window. In othersystems and methods disclosed herein, additional vehicle components mayalso be included in the plastic glazing. Such components may include,for example, a colored translucent portion for a rear light unit; anadditional translucent portion for a courtesy light, a license platelight, or other light unit; a cavity and fixation unit (e.g., a threadedhole, a hook or clip) for supporting a light unit; a cavity and fixationunit for supporting a license plate; a textured and/or raised region fora logo or other marking; a spoiler or other aerodynamic feature; anopening that serves as a ventilation opening; and the like.

In particular, systems and methods disclosed herein may also provide animprovement over existing vehicles having separate light units. Lightunits in many conventional vehicles are typically self-contained andseparate from the other components of the vehicle. Each light unittypically requires its own housing unit and lens. Systems and methodsdisclosed herein provide an improvement over such existing systems byproviding a light unit that is integrated with other components of avehicle. Specifically, systems and methods disclosed herein may providea plastic glazing of a tailgate that may function as a lens of a lightunit. Systems and methods disclosed herein may also provide a housingstructure for a tailgate that may function as the housing unit formultiple different light units. Accordingly, systems and methodsdisclosed herein eliminate the need for having a separate light unit ina vehicle. Such systems and methods allow a light source to be supportedwithin a housing of a tailgate and to use a plastic glazing of thetailgate as its lens. As such, such systems and methods disclosed hereinreduce a number of components of a vehicle's light units, therebyreducing a cost of manufacturing and assembling the vehicle.

Systems and methods disclosed herein may provide a tailgate having anintegrated lighting system that conforms to certain federal regulatoryrequirements and/or international standards for vehicle lighting. Forexample, certain international standards, such as, for example, ECERegulation No. 48 and SAE Standard J578, may require specific colors oflight be emitted from a lighting device for a vehicle. In systems andmethods disclosed herein, a light source (e.g., a LED) may be positionedbehind a plastic glazing. The color of the plastic glazing may shift thecolor of the light from the light source. Accordingly, if light sourcesfrom existing lighting systems are used, the color of the light emittedfrom the plastic glazing into the surrounding environment may no longerbe in conformance with certain legal requirements. Systems and methodsdisclosed herein, however, may use light sources having adjusted colorsthat compensate for the color shift of the plastic glazing.Alternatively, systems and methods disclosed herein may use componentsfor forming a plastic glazing having colors that enable a transmissionof light within the legal color space when used with existing lightsources. As such, systems and methods disclosed herein provide a methodfor accounting for a color shift resulting from the use of a coloredplastic glazing, such as, for example, a plastic glazing having a greenor brown glazing color. A colored plastic glazing may especially bedesirable for privacy tinting purposes.

Systems and methods disclosed herein may also provide a tailgate havinginterior lighting functions. Many individuals desire having interiorlighting in a vehicle for both functional and aesthetical purposes. Forexample, interior lighting may be used to provide a unique ambiencewithin a vehicle. As another example, lights designed to illuminate aninterior of the vehicle may serve certain guiding functions. Theinclusion of interior lights oftentimes may add to the expense ofmanufacturing and assembling a vehicle due to the need for additionallighting components. Systems and methods disclosed herein, however, mayprovide a method for integrating an interior lighting feature into aplastic glazing of a tailgate of a vehicle. The interior lightingfeature may be formed as part of an injection molding process forforming the plastic glazing of the tailgate. Accordingly, such systemsand methods may reduce a number of additional components needed for theinterior lighting feature. Because the injection molding process may bemachine-automated, such systems and methods may also automate theprocess for forming the interior lighting feature.

Systems and methods disclosed herein may also provide a tailgate havingapplique lighting. The tailgate may have a plastic glazing that isformed with a plurality of depressions, each for receiving acorresponding lens or cover component of the applique lighting. Thedimensions of the depressions in the plastic glazing and the dimensionsof the cover components may be designed to have an interference fitbetween them, such as, for example, a 0.1 mm interference fit. Thedimension of the thickness or height of the cover may be configured suchthat the cover, when placed within the depression, forms a surface thatis flush with a surrounding region of the plastic glazing. In apreferred embodiment of the present disclosure, the applique lightingmay be in the shape of letters or other graphic designs. The height andwidth of the letters may vary depending on the desired appearance of theapplique lighting.

Systems and methods disclosed herein may also provide a tailgate thatreduces a number of inhomogeneities, seams, and other disruptions,interruptions, and gaps along a surface of a vehicle, thereby increasingan aesthetic appearance of the vehicle and increasing aerodynamicperformance. Systems and methods disclosed herein further may provide atailgate that conceals one or more other features of a vehicle, such as,for example, a light unit, thereby increasing an aesthetic appearance ofthe vehicle.

Systems and methods disclosed herein may also provide a method ofmanufacturing a tailgate or, specifically, a plastic glazing of atailgate. Such systems and methods may provide a method of producing aplastic glazing using multi-shot injection molding techniques. Forexample, in certain aspects of the disclosure, a plastic glazing of atailgate may be formed via a three-shot injection molding process. In afirst shot, a clear thermoplastic polymer may be injected to form ashell or outline of the plastic glazing. In a second shot, a coloredthermoplastic polymer may be injected to form one or more coloredregions in the plastic glazing. For example, a red thermoplastic polymermay be injected to form a red translucent region to serve as the lensfor a rear light of a vehicle.

Referring now to FIG. 1, an exemplary plastic glazing 100 of a tailgateof a vehicle is depicted. The plastic glazing 100 may be a one-piecemonolithic structure formed of one or more thermoplastic polymers.Examples of suitable thermoplastic polymers include: polycarbonate,polyester carbonate, poly methyl methacrylate, and the like. Accordingto a preferred aspect of the disclosure, the plastic glazing 100 may beformed of a polycarbonate. The plastic glazing 100 can have an outersurface that is seamless, i.e., lacking any visual openings, junctions,disruptions, interruptions, gaps, or the like.

The plastic glazing 100 has a first colored portion 102 that functionsas a portion of a right tail lamp of the vehicle, and a second coloredportion 104 that functions as a portion of a left tail lamp of thevehicle. In particular, the colored portions 102, 104 can function aslenses of the tail lamps of the vehicle. The plastic glazing 100 alsohas a third portion 106 for an additional light unit such as, forexample, an axillary brake light or a courtesy light. The plasticglazing 100 also includes a clear transparent portion 108 that functionsas a rear window of the vehicle, and a colored non-transparent portion110. The colored non-transparent portion may be strategically placed tohide one or more structures positioned behind the plastic glazing 100.

Referring now to FIG. 2, a housing unit 200 of a tailgate is depicted.The housing unit 200 may be formed of a fiber-reinforced polymer.According to a preferred aspect of the disclosure, the housing unit 200may be formed of a long-glass fiber-reinforced polypropylene such as,for example, SABIC® STAMAX™ plastic. As depicted in FIG. 2, the housingunit 200 comprises one or more cavities for receiving a light unit. Inparticular, the housing unit 200 comprises a first cavity 212 forreceiving a first light unit 202, a second cavity 214 for receiving asecond light unit 204, and a third cavity 216 for receiving a thirdlight unit 206. The light units 202, 204, 206 can be fixed directly ontothe housing unit 200 via access doors and/or using mechanical fasteners(e.g., screw, bolt, and the like). The cavities 212, 214, 216 canprevent light from the light units from bleeding outside of a confinedspace. As such, additional cavities (not depicted) may be formed next tothe cavities 212, 214, 216 for holding additional light units, and thecavities would prevent the light generated by one light unit frombleeding into a space reserved for another light unit.

The light units 202, 204, 206 may be a single type of light unit. Forexample, the light units 202, 204, 206 can be brake light units.Alternatively, the light units 202, 204, 206 may comprise more than onekind of light unit. For example, the light units 202, 204 can be brakelight units, and the light unit 206 can be a courtesy light unit.

The plastic glazing 100 may be secured to the housing unit 200 such thatthe light units 202, 204, 206 are disposed between the plastic glazing100 and the housing unit 200. In particular, the plastic glazing 100 maybe secured to the housing unit 200 such that the light units 202, 204,206 are disposed behind the portions 102, 104, 106 (depicted in FIG. 1).The light unit 202 may be disposed behind the first colored portion 102,the light unit 204 may be disposed behind the second colored portion104, and the light unit 206 may be disposed behind the third portion106.

Each of the light units 202, 204, 206 may comprise a light source thatgenerates a white or a colored light. The light generated by the lightunits 202, 204, 206 may pass through the portions 102, 104, 106,respectively.

Light emitted from the light units 202, 204, 206 through the portions102, 104, 106 of the plastic glazing 100 may be emitted as a coloredlight in accordance with certain international standards governingvehicle lighting such as, for example, ECE Regulation No. 48 and SAEStandard J578. As noted above, the portions 102, 104 can function as thelens for the vehicle's tail lamps. Accordingly, light emitted from thelight units 202, 204 through the portions 102, 104 may be red. ECERegulation No. 48 defines the color “red” as emitted light withchromaticity coordinates (x,y) that lie within the chromaticity areasdefined by the following boundaries in the CIE xyY color space:

R₁₂ yellow boundary: y = 0.335 R₂₃ the spectral locus R₃₄ the purpleline R₄₁ purple boundary: y = 0.980 − xWith the following (x,y) intersection points:

R₁: (0.645,0.335)

R₂: (0.665,0.335)

R₃: (0.735,0.265)

R₄: (0.721,0.259)

Thus, to fulfill this regulation, the light emitted through the portions102, 104 may have chromaticity coordinates (x,y) that fall within thechromaticity area defined for the color red in ECE Regulation No. 48, asset forth above.

While the portions 102, 104 and the light units 202, 204 are describedherein as producing a red light, one of ordinary skill in the art wouldappreciate that the portions 102, 104 and the light units 202, 204 mayalso be designed to produce lights having other colors, such as, forexample, yellow or amber. These colors are also defined in ECERegulation No. 48 as well as in other international standards.

The housing unit 200 also includes an opening 208. When the plasticglazing 100 is secured to the housing unit 200 such that the light units202, 204, 206 line up with the portions 102, 104, 106, the opening 208may line up with the clear transparent portion 108 of the plasticglazing 100. By lining up with the clear transparent portion 108, theopening 208 allows an individual's view through the transparent portion108 (which, as described above, may function as the rear window of thevehicle) to remain unobstructed.

Each of the light units 202, 204, 206 may include one or more lightcomponents such as, for example, an incandescent lamp, anelectroluminescent lamp, a gas discharge lamp, and the like. Because thelight units 202, 204, 206 are secured directly onto the housing unit200, a separate housing for each light unit 202, 204, 206 may not beneeded. Thus, the housing unit 200, which serves as the structuralcarrier for the plastic glazing 100 of the tailgate, integrates ahousing function of a light unit. Moreover, because the portions 102,104, 106 may function as the lens of a light unit—i.e., the portion 102may function as the lens for the light unit 202, the portion 104 mayfunction as the lens for the light unit 204, and the portion 106 mayfunction as the lens for the light unit 206—a separate lens for eachlight units 202, 204, 206 also may not be needed.

The plastic glazing 100 may be secured to the housing unit 200 using anadhesive and/or a mechanical fastening system (e.g., a screw bolt orclip fastening system). The adhesive used may be a commerciallyavailable adhesive that is typically used in the automotive industry forthe adhesive bonding of plastic components. Such adhesives may include,for example, wet adhesives, contact adhesives, hot-melt adhesives, orreaction adhesives. The thickness of the adhesive required may varydepending on the specific geometries of the plastic glazing 100 and thehousing unit 200. When the adhesive is a hot-melt adhesive that can beprocessed under thermoplastic conditions, it may be possible to bond theplastic glazing 100, the housing unit 200, and the hot-melt adhesivetogether during a multi-shot injection molding process.

While the tailgate including the plastic glazing 100 and the housingunit 200 is depicted as having three light units 202, 204, 206, one ofordinary skill in the art would appreciate that the tailgate cancomprise less or more light units. Such light units may include, forexample, license plate lamps, turn signal lamps, backup lamps, and thelike.

FIGS. 3 and 4 present alternative embodiments of a partialcross-sectional view of the plastic glazing 100 depicted in FIG. 1 witha portion of a housing unit (e.g., the housing unit 200) disposed behindthe plastic glazing 100. In FIG. 3, a first embodiment is shown wherethe plastic glazing 100 is formed of a first component 302, a secondcomponent 304, and a third component 310. The first component 302, thesecond component 304, and the third component 310 may be formed ofthermoplastic polymers, such as, for example, polycarbonate resins. Thefirst component 302 and the second component 304 may be translucent, andthe third component 310 may be non-transparent. An overlapping portionof the first component 302 and the second component 304 may form thecolored portion 104.

A light source 308 of the light unit 204 may be disposed behind thecolored portion 104. The light source 308 may emit light beams thattravel through the colored portion 104 to an exterior of the vehicle.The light source 308 may be supported by a portion 306 of the housingunit 200. The portion 306 may form the cavity 214 for receiving thelight unit 204. The light source 308 may be mounted to the housing unit200 using a fixation mechanism (e.g., a screw system, an adhesive, andthe like).

When the light beams emitted by the light source 308 travel through theoverlapping portion of the first component 302 and the second component304 (i.e., the colored portion 104), their color, intensity, anddirection of travel can be altered depending on the properties of thefirst component 302 and the second component 304. Relevant propertiesmay include, for example, the colors of the first component 302 and thesecond component 304, the thicknesses of the first component 302 and thesecond component 304, the internal molecular structure of the firstcomponent 302 and the second component 304, etc. As such, theseproperties can be adjusted to achieve a certain desired color of emittedlight, at a certain dispersion level and at a certain intensity.

As described above, certain international standards such as ECERegulation No. 48 and SAE Standard J578 may define certain colorrequirements for particular types of vehicle lights. For example, theU.S. Department of Transportation requires that vehicle tail lamps emita red colored light in accordance with SAE Standard J578. SAE StandardJ578 defines a red light as a light having a chromaticity value thatfalls within the color space defined by yellow boundary corresponding toy=0.33 and a purple boundary corresponding to y=0.98−x. ECE RegulationNo. 48 sets forth the same standard. The U.S. Department ofTransportation also requires that turn signal lights on vehicles emit ared or amber colored light. SAE Standard J578 defines an amber light asa light having a chromaticity value that falls within the color spacedefined by a red boundary corresponding to y=0.39, a white boundarycorresponding to y=0.79−0.67x, and a green boundary corresponding toy=x−0.12.

In a preferred aspect of the disclosure, the colors of the firstcomponent 302 and the second component 304 may be selected, taking intoaccount the color of the light emitted by the light source 308, suchthat the color of the light emitted through the plastic glazing 100 mayfall within the color space defined required by federal regulations, asdefined by the SAE Standard J578 or another international standard. Ifthe light source 308 emits a white light, then the colors of the firstcomponent 302 and the second component 304 may be selected such thatthey impart a red color to the white light as it passes through thefirst component 302 and the second component 304. If the light source308 emits a colored light, then different colors for the first component302 and the second component 304 may be selected such that the color ofthe colored light shifts accordingly to meet regulatory requirementswhen it passes through the first component 302 and the second component304.

The colors of the first component 302 and the second component 304 mayalso be adjusted to account for their individual colors. For example,the first component 302 may form a rear window of the vehicle. Thus, itmay be desirable to have the first component 302 have a green or browntint. Such may undesirably shift the color of any light that passesthrough the first component 302 away from the red or amber colorrequired by federal regulations. Accordingly, in an effort to avoidfalling out of the legal color space, the color of the second component304 can be selected such that it accounts for the undesirable colorshift that the first component 302 will produce.

While FIGS. 3 and 4 depicts a light source 308 that is disposed behindan overlapping portion of two translucent components (e.g., the firstcomponent 302 and the second component 304), one of ordinary skill inthe art would appreciate that a single translucent component may operatewith the light source 308 to generate a light in accordance withinternational lighting standards and federal regulations. In certainaspects, the light source 308 may also generate a colored light. Thus,the color of the translucent component through which the generated lighttravels also can be selected to account for the color of the lightgenerated by the light source 308 such that the light that emerges fromthe translucent component is in accordance with international lightingstandards and federal regulations. In other words, the combination ofthe color of the light source 308 and the color of the translucentcomponent can be selected such that they produce together a light thatis in accordance with international lighting standards and federalregulations. In certain aspects, an additional component (e.g., aseparate lens structure) may be placed behind the translucent componentof the plastic glazing to further adjust the color and dispersioncharacteristics of the light that is generated by the light source 308.This additional component may be supported by a housing unit of thetailgate that is disposed behind the translucent component.

The third component 310 may be a non-transparent so that it forms aregion of blackout (e.g., opaque or substantially opaque) adjacent tothe overlapping portion of the first component 302 and the secondcomponent 304 (i.e., the colored portion 104). The third component 310may be black or be another color and/or effect. This region of blackoutmay be configured to conceal the sections of the portion 306 of thehousing unit 200 that are attached to the plastic glazing 100, and anyadhesive or other fixation mechanism used to attach the housing unit 200to the plastic glazing 100.

Referring now to FIG. 4, a second embodiment of the partialcross-sectional view of the plastic glazing 100 depicted in FIG. 1 withthe portion 306 of the housing unit is depicted. In this secondembodiment, the second component 304 may be replaced with a fourthcomponent 312 having a textured surface 314. The textured surface 314may be configured to affect a dispersion of light beams that travelthrough the fourth component 312. Similar to the second component 304depicted in FIG. 3, the fourth component 312 may be disposed behind thefirst component 302, and an overlapping region of the first component302 and the fourth component 312 may form a lens for the light unit 204(depicted in FIG. 2). Light that is emitted by the light source 308 ofthe light unit 204 may travel through the overlapping region of thefirst component 302 and the fourth component 312. Thus, the texturedsurface of the fourth component 312 may be used to affect the dispersionof light travelling through the overlapping region of the firstcomponent 302 and the fourth component 312. In certain aspects of thedisclosure, the textured surface of the fourth component 312 may beconfigured such that it creates an aesthetical pattern in the light thatis emitted from the overlapping region of the first component 302 andthe fourth component 312 (i.e., the colored portion 104). In otheraspects of the disclosure, the textured surface of the fourth component312 may be configured such that it controls the dispersion of lightthrough the colored portion 104 to conform to certain regulatoryrequirements. As such, the textured surface of the fourth component 312may be configured to achieve either an aesthetical or functional effect.

Referring now to FIG. 5, an exemplary plastic glazing 400 of a tailgateof a vehicle is depicted. The plastic glazing 400 may be of one-piecemonolithic molded plastic construction, and may have an outer surfacethat is substantially free of any inhomogeneities, seams, and otherdisruptions, interruptions, and gaps. The plastic glazing 400 maycomprise a portion 406 that functions as a lens of a first light unit, aportion 410 that functions as a lens of a second light unit, and aportion 404 that functions as a rear window of the vehicle. The plasticglazing 400 may also comprise a non-transparent portion 402, which canconceal one or more other vehicle components.

Additionally, the plastic glazing 400 may comprise a logo or marking408. The logo 408 may be raised from a region of the plastic glazing 400that surround it. The logo 408 may be an example of a raised marking.Further details of the logo 408 are described with reference to FIG. 8below.

FIG. 6 depicts an outer panel 500 of the vehicle which is designed toattach to the plastic glazing 400. The outer panel of the vehicle mayinclude a main body 502 and an opening 504 through which the logo 408may fit, as depicted in FIG. 7.

FIG. 8 depicts a partial cross-sectional view of the plastic glazing 400along a line B-B, which passes through the logo 408. As depicted in FIG.8, the logo 408 may be formed of two components, a first component 424and a second component 422 surrounding the first component 424. Thefirst component 424 and the second component 422 can be selected to beclear or colored, and transparent, translucent, or non-transparent. In apreferred aspect of the disclosure, at least one of the first component424 and the second component 422 is translucent such that a lightdisposed behind the plastic glazing towards an interior of the vehiclemay shine through the translucent component to increase the visibilityof the logo 408, especially when it is dark. The first component 424 andthe second component 422 of the logo 408 may be raised from a component420 which forms a main body of the plastic glazing, including thenon-transparent portion 402. The logo 408 can be raised from the rest ofthe plastic glazing 400 so that it can fit through the opening 504 ofthe outer panel 500.

The first component 424 and the second component 422 may be formed of athermoplastic polymer. The first component 424 and the second component422 may be formed as part of an injection molding process for formingthe plastic glazing 400. In a first shot, a first material may beinjected into a mold cavity having a first volume to form the component420. Then, in later shots, the first component 424 and the secondcomponent 422 of the logo 408 may be molded onto the component 420. Thefirst component 424 and the second component 422 may bind to thecomponent 420 through melt bonding. To enable optimal bonding betweenthe separate components, the first component 424 and the secondcomponent 422 of the logo 408 as well as the component 420 may be formedof a similar thermoplastic polymer, e.g., different colors ofpolycarbonate resin.

While the logo 408 is depicted as having a first component 424 and asecond component 422 in FIG. 8, one or ordinary skill in the art wouldappreciate that raised markings with more or less components may beused. In certain aspects, a plastic glazing may have a logo that isformed as part of the same component as the main body of the plasticglazing. In such an aspect, the logo may be formed when the componentforming the main body is molded using an injection molding technique.

Referring now to FIG. 9, an exemplary plastic glazing 700 of a tailgateof a vehicle is depicted. The plastic glazing 700 may also be ofone-piece monolithic molded plastic construction, and may have an outersurface that is substantially free of any inhomogeneities, seams, andother faults. The plastic glazing 700 may comprise a main body 702. Themain body 702 may have a first translucent portion 704 that istransparent that functions as a rear window of the vehicle. The mainbody 702 may also have a second translucent portion 706 that functionsas a lens of a light unit 726 (depicted in FIG. 10).

Because the plastic glazing 700 does not include any seams or breaksalong its different components, the light unit 726 behind the secondtranslucent portion 706 may be concealed from the outside until thelight unit 726 is turned on.

FIG. 10 depicts a cross-section of the plastic glazing 700 along theline E-E. As depicted in FIG. 10, the light unit 726 can be supported inposition by a portion of a housing unit 724. The housing unit 724 may bea portion of an overall housing unit of the tailgate, such as, forexample, the housing unit 200 depicted in FIG. 2. The housing unit 724may be attached to the plastic glazing 700 using an adhesive or otherfixation mechanism. The plastic glazing 700 may be formed of a pluralityof different components that are molded to one another. The plurality ofdifferent components may include a first component 708, a secondcomponent 722, and a third component 710. The first component 708 canform a first layer of the plastic glazing 700. The second component 722and the third component 710 can be disposed on certain regions of thefirst component 708. The second component 722 can comprise a transparentthermoplastic polymer. An overlapping portion of the first component 708and the second component 722 may correspond to the first translucentportion 704 depicted in FIG. 9. The third component 710 may comprise anon-transparent thermoplastic polymer. As such, the third component 710can be used to conceal one or more other vehicle components disposedbehind the third component 710.

As depicted in FIG. 10, the portion of the housing unit 724 supportingthe light unit 726 may attach to the third component 710 of the plasticglazing 700. In a preferred aspect of the disclosure where the thirdcomponent 710 comprises a non-transparent polymer, the third component710 may conceal those portions of the housing unit 724 that attached tothe plastic glazing 700 along sections where the third component 710 isdisposed. The third component 710 may be specifically disposed at thosesections of the plastic tailgate 700 where the housing unit 724 attachesto the plastic glazing 700.

Referring now to FIG. 11, an enlarged view of an upper region labeled Fof the cross-sectional view of the plastic glazing 700 is depicted. Asshown in the enlarged view, the first component 708 of the plasticglazing 700 may further comprise two fixation mechanisms 714, 716 forfixing a second light unit 712 to the vehicle. The second light unit 712may be an interior light unit that projects light through the firstcomponent 708, which may be formed of a clear or colored translucentthermoplastic polymer. The second light unit 712 may be secured to thevehicle using any number of known fixation methods. For example, thelight unit may be secured to the vehicle by being snapped into placebetween the two fixation mechanisms 714, 716. The light unit may also besecured to the vehicle using screws, bolts, or other fastening membersthat can be fixed to the fixation mechanisms 714, 716.

Additionally, as depicted in FIG. 11, the tailgate including the plasticglazing 700 may further include a spoiler portion 720 and a supportingmember 718. The supporting member 718 may be a part of a housing unit(e.g., the housing unit 724) that is disposed behind the plastic glazing700 for supporting light units and the like. The spoiler portion 720 maybe formed of an additional thermoplastic polymer and may be attached tothe main body 702 using an adhesive or mechanical fastening system.

According to certain aspects of the disclosure, the tailgate assemblesdisclosed herein may also include additional layers on top of thethermoplastic polymer layers. For example, a layer for increasingscratch resistance may be added to an exterior surface of the plasticglazing. As another example, an additional layer for adding more supportto the thermoplastic polymer layers may also be added to an interiorsurface of the plastic glazing. This additional layer may be formed of aplastic, a metal, or other material for increasing the structuralstrength of the tailgate.

It will be appreciated that the present disclosure may include any oneand up to all of the following examples.

Example 1

A plastic glazing of a tailgate of a vehicle, the plastic glazingcomprising: a first translucent component; a second translucentcomponent molded onto the first translucent component, wherein thesecond translucent component comprises a color, wherein the plasticglazing is of one-piece molded plastic construction, wherein anoverlapping portion of the first translucent component and the secondtranslucent component forms a lens of a first light unit.

Example 2

The plastic glazing of Example 1, wherein the first translucentcomponent is clear thermoplastic polymer.

Example 3

The plastic glazing of Example 2, wherein the clear thermoplasticpolymer comprises polycarbonate.

Example 4

The plastic glazing of Example 1, wherein the first translucentcomponent is a colored thermoplastic polymer.

Example 5

The plastic glazing of Example 4, wherein the clear thermoplasticpolymer comprises polycarbonate.

Example 6

The plastic glazing of Example 1, wherein the first light unit is a taillamp.

Example 7

The plastic glazing of Example 1, wherein the first light unit is turnsignal light.

Example 8

The plastic glazing of Example 1, wherein the first light unit is abackup lamp.

Example 9

The plastic glazing of any of Examples 1-6, wherein the overlappingportion of the first translucent component and the second translucentcomponent is configured to transmit a red light having a CIE (x,y)chromaticity value within a color space defined by a yellow boundarycorresponding to y=0.33 and a purple boundary corresponding to y=0.98−x.

Example 10

The plastic glazing of any of Examples 1-5 and 7, wherein theoverlapping portion of the first translucent component and the secondtranslucent component is configured to transmit an amber light having aCIE (x,y) chromaticity value within a color space defined by a redboundary corresponding to y=0.39, a white boundary corresponding toy=0.79−0.67x, and a green boundary corresponding to y=x−0.12.

Example 11

The plastic glazing of any of Examples 1-5 and 8, wherein theoverlapping portion of the first translucent component and the secondtranslucent component is configured to transmit a white light having aCIE (x,y,) chromaticity value within a color space defined by a blueboundary corresponding to x=0.31, a yellow boundary corresponding tox=0.50, a first green boundary corresponding to y=0.15+0.64x, a purpleboundary corresponding to y=0.05+0.75x, a second green boundarycorresponding to y=0.44, and a red boundary corresponding to y=0.38.

Example 12

The plastic glazing of any of Examples 1-5, further comprising a thirdtranslucent component molded onto the first translucent component,wherein an overlapping portion of the first translucent component andthe third translucent component forms a lens of a second light unit.

Example 13

The plastic glazing of Example 12, wherein the overlapping portion ofthe first translucent component and the second translucent component isconfigured to transmit a red light having a CIE (x,y) chromaticity valuewithin a color space defined by a yellow boundary corresponding toy=0.33 and a purple boundary corresponding to y=0.98−x, and wherein theoverlapping portion of the first translucent component and the thirdtranslucent component is configured to transmit an amber light having aCIE (x,y) chromaticity value within a color space defined by a redboundary corresponding to y=0.39, a white boundary corresponding toy=0.79−0.67x, and a green boundary corresponding to y=x−0.12.

Example 14

The plastic glazing of Example 13, wherein the overlapping portion ofthe first translucent component and the second translucent component andthe overlapping portion of the first translucent component and the thirdtranslucent component are adjacent to each other.

Example 15

The plastic glazing of any of Examples 1-5, wherein the overlappingportion of the first translucent component and the second translucentcomponent is configured to transmit a light having a percentage of raysthat deviates by more than 2.5° from an incident ray of less than orequal to 30 percent.

Example 16

The plastic glazing of any of Examples 1-5, wherein the plastic glazingis attached to a housing unit that is configured to support the firstlight unit.

Example 17

The plastic glazing of Example 16, wherein the housing unit comprises afiber-reinforced polymer.

Example 18

The plastic glazing of Example 17, wherein the fiber-reinforced polymercomprises polypropylene.

Example 19

The plastic glazing of any one of Examples 1-5, wherein at least one ofthe first translucent component and the second translucent componentcomprises a textured surface.

Example 20

The plastic glazing of Example 19, wherein the textured surface isconfigured to disperse light passing through the overlapping portion ofthe first translucent component and the second translucent component.

Example 21

The plastic glazing of any one of Examples 1-5, wherein the plastictailgate is produced using a multi-shot injection molding process.

Example 22

The plastic glazing of Example 21, wherein the second translucentcomponent is molded onto the first translucent component in a secondshot of the multi-shot injection molding process.

Example 23

The plastic glazing of any one of Examples 1-5, wherein the secondtranslucent component is disposed behind the first translucent componenttowards an interior of the vehicle.

Example 24

The plastic glazing of any one of Examples 1-5, wherein the firsttranslucent component forms a raised marking.

Example 25

The plastic glazing of Example 24, wherein the raised marking is a logo.

Example 26

The plastic glazing of Example 25, wherein the logo is configured to beilluminated by a light unit disposed behind the plastic glazing towardsan interior of the vehicle.

Example 27

The plastic glazing of any one of Examples 25 and 26, wherein the logois formed during an injection molding process.

Example 28

The plastic glazing of any one of Examples 1-5, further comprising alaser mark.

Example 29

The plastic glazing of Example 28, wherein the laser mark is configuredto be illuminated by a light unit disposed behind the plastic glazingtowards an interior of the vehicle.

Example 30

The plastic glazing of any of Example 1-5, wherein a different portionof the first translucent component forms a lens of a third light unit.

Example 31

The plastic glazing of Example 30, wherein the third light unit is apuddle light.

Example 32

The plastic glazing of Example 30, wherein the third light unit is alicense plate light.

Example 33

The plastic glazing of Example 30, wherein the third light unit is aninterior light.

Example 34

A plastic glazing of a tailgate of a vehicle, the plastic glazingcomprising: a first translucent component; a second translucentcomponent molded onto the first translucent component, wherein thesecond translucent component comprises a color, wherein the plasticglazing is of one-piece molded plastic construction, wherein a portionof one or more of the first translucent component and the secondtranslucent component forms a lens of a first molded light assembly.

Example 35

The plastic glazing of Example 34, wherein the first molded lightassembly comprises a light source that is configured to generate a lightthat passes through an overlapping portion of the first translucentcomponent and the second translucent component.

Example 36

The plastic glazing of any one of Examples 34-35, wherein the portion ofone or more of the first translucent component and the secondtranslucent component forming the lens of the first molded lightassembly is configured to operate with the light source to produce a redlight having a CIE (x,y) chromaticity value within a color space definedby a yellow boundary corresponding to y=0.33 and a purple boundarycorresponding to y=0.98−x.

Example 37

The plastic glazing of any one of Examples 34-36, further comprising athird translucent component molded onto the first translucent component,wherein at least a portion of the third translucent component forms alens of a second molded light assembly.

Example 38

The plastic glazing of any one of Examples 34-37, wherein the portion ofthe third translucent component forming the lens of the second moldedlight assembly is configured to operate with the second molded lightassembly to produce an amber light having a CIE (x,y) chromaticity valuewithin a color space defined by a red boundary corresponding to y=0.39,a white boundary corresponding to y=0.79−0.67x, and a green boundarycorresponding to y=x−0.12.

Example 39

The plastic glazing of any one of Examples 34-38, wherein the portion ofthe third translucent component forming the lens of the second moldedlight assembly is configured to operate with the second molded lightassembly to produce a white light having a CIE (x,y) chromaticity valuewithin a color space defined by a blue boundary corresponding to x=0.31,a yellow boundary corresponding to x=0.50, a first green boundarycorresponding to y=0.15+0.64x, a purple boundary corresponding toy=0.05+0.75x, a second green boundary corresponding to y=0.44, and a redboundary corresponding to y=0.38.

Example 40

The plastic glazing of any one of Examples 34-39, wherein a differentportion of the first translucent component forms a lens of a thirdmolded light assembly, wherein the third molded light assembly comprisesone of a puddle light, a license plate light, and an interior light.

Example 41

The plastic glazing of any one of Examples 34-40, wherein the portion ofone or more of the first translucent component and the secondtranslucent component forming the lens of the first molded lightassembly and the portion of the third translucent component forming thelens of the second molded light assembly are adjacent to each other.

Example 42

The plastic glazing of any one of any one of Examples 34-41, wherein theplastic glazing is attached to a housing unit that is configured tosupport the first molded light assembly, wherein the housing unitcomprises a fiber-reinforced polymer.

Example 43

The plastic glazing of any one of Examples 34-42, wherein at least oneof the first translucent component and the second translucent componentcomprises a textured surface configured to disperse light passingthrough the overlapping portion of the first translucent component andthe second translucent component.

Example 44

The plastic glazing of any one of Examples 34-43, wherein theoverlapping portion of the first translucent component and the secondtranslucent component is configured to transmit a light having apercentage of rays that deviates by more than 2.5° from an incident rayof less than or equal to 30 percent.

Example 45

The plastic glazing of any one of Examples 34-44, wherein the plasticglazing is attached to a housing unit that is configured to support thefirst molded light assembly.

Example 46

The plastic glazing of any one any of Examples 34-45, wherein theplastic tailgate is produced using a multi-shot injection moldingprocess.

Example 47

The plastic glazing of any one of Examples 34-46, wherein the secondtranslucent component is molded onto the first translucent component ina second shot of the multi-shot injection molding process.

Example 48

The plastic glazing of any one of Examples 34-47, wherein the firsttranslucent component forms a raised marking.

In general, systems and methods disclosed herein may alternatelycomprise, consist of, or consist essentially of, any appropriatecomponents herein disclosed. The invention may additionally, oralternatively, be designed so as to be devoid, or substantially free, ofany components used in the prior art compositions or that are otherwisenot necessary to the achievement of the function and/or objectives ofthe present invention.

Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context.

Aspects of the present disclosure described in connection withillustrated embodiments have been presented by way of illustration, andthe present disclosure is therefore not intended to be limited to thedisclosed embodiments. Furthermore, the structure and features of eachembodiment described herein can be applied to the other embodimentsdescribed herein. Accordingly, those skilled in the art will realizethat the present disclosure is intended to encompass all modificationsand alternative arrangements included within the spirit and scope of thepresent disclosure, as set forth by the appended claims.

1. A plastic glazing of a tailgate of a vehicle, the plastic glazingcomprising: a first translucent component; and a second translucentcomponent molded onto the first translucent component, wherein thesecond translucent component comprises a color, wherein the plasticglazing is of one-piece molded plastic construction, and wherein aportion of one or more of the first translucent component and the secondtranslucent component forms a lens of a first molded light assembly. 2.The plastic glazing of claim 1, wherein the first molded light assemblycomprises a light source that is configured to generate a light thatpasses through an overlapping portion of the first translucent componentand the second translucent component.
 3. The plastic glazing of claim 2,wherein the portion of one or more of the first translucent componentand the second translucent component forming the lens of the firstmolded light assembly is configured to operate with the light source toproduce a red light having a CIE (x,y) chromaticity value within a colorspace defined by a yellow boundary corresponding to y=0.33 and a purpleboundary corresponding to y=0.98−x.
 4. The plastic glazing of claim 3,further comprising a third translucent component molded onto the firsttranslucent component, wherein at least a portion of the thirdtranslucent component forms a lens of a second molded light assembly. 5.The plastic glazing of claim 4, wherein the portion of the thirdtranslucent component forming the lens of the second molded lightassembly is configured to operate with the second molded light assemblyto produce an amber light having a CIE (x,y) chromaticity value within acolor space defined by a red boundary corresponding to y=0.39, a whiteboundary corresponding to y=0.79−0.67x, and a green boundarycorresponding to y=x−0.12.
 6. The plastic glazing of claim 4, whereinthe portion of the third translucent component forming the lens of thesecond molded light assembly is configured to operate with the secondmolded light assembly to produce a white light having a CIE (x,y)chromaticity value within a color space defined by a blue boundarycorresponding to x=0.31, a yellow boundary corresponding to x=0.50, afirst green boundary corresponding to y=0.15+0.64x, a purple boundarycorresponding to y=0.05+0.75x, a second green boundary corresponding toy=0.44, and a red boundary corresponding to y=0.38.
 7. The plasticglazing of claim 6, wherein a different portion of the first translucentcomponent forms a lens of a third molded light assembly, wherein thethird molded light assembly comprises one of a puddle light, a licenseplate light, and an interior light.
 8. The plastic glazing of claim 5,wherein the portion of one or more of the first translucent componentand the second translucent component forming the lens of the firstmolded light assembly and the portion of the third translucent componentforming the lens of the second molded light assembly are adjacent toeach other.
 9. The plastic glazing of claim 1, wherein the plasticglazing is attached to a housing unit that is configured to support thefirst molded light assembly, wherein the housing unit comprises afiber-reinforced polymer.
 10. The plastic glazing of claim 1, wherein atleast one of the first translucent component and the second translucentcomponent comprises a textured surface configured to disperse lightpassing through the overlapping portion of the first translucentcomponent and the second translucent component.
 11. The plastic glazingof claim 1, wherein the overlapping portion of the first translucentcomponent and the second translucent component is configured to transmita light having a percentage of rays that deviates by more than 2.5° froman incident ray of less than or equal to 30 percent.
 12. The plasticglazing of claim 1, wherein the plastic glazing is attached to a housingunit that is configured to support the first molded light assembly. 13.The plastic glazing of claim 1, wherein the plastic tailgate is producedusing a multi-shot injection molding process.
 14. The plastic glazing ofclaim 1, wherein the second translucent component is molded onto thefirst translucent component in a second shot of the multi-shot injectionmolding process.
 15. The plastic glazing of claim 1, wherein the firsttranslucent component forms a raised marking.